Brake pads rattling in caliper housing....

For the past several weeks I have noticed a sound that appears to be the brake pads rattling within the caliper housing on the front wheels under certain specific conditions. It is only noticable when I am turning a corner slowly without my foot on the brake, window open. When I hit a small bump or crease in the pavement, I will notice the rattle sound. If foot is on the brake and they are gently applied; no rattle. Brakes work perfectly at all times. Bad return springs? Anti-rattle springs?? Anyone??? New Sept. 2010. 6600 miles. Prius II. Silver. Clean windows. Smelly running shoes in rear compartment. NOTE: At 5000 mile service there was no sound.

For the past several weeks I have noticed a sound that appears to be the brake pads rattling within the caliper housing on the front wheels under certain specific conditions. It is only noticable when I am turning a corner slowly without my foot on the brake, window open. When I hit a small bump or crease in the pavement, I will notice the rattle sound. If foot is on the brake and they are gently applied; no rattle. Brakes work perfectly at all times. Bad return springs? Anti-rattle springs?? Anyone??? New Sept. 2010. 6600 miles. Prius II. Silver. Clean windows. Smelly running shoes in rear compartment. NOTE: At 5000 mile service there was no sound.

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This is a known issue. (at least for many on this board) So far, I have yet to come across an official fix from Toyota. It took 3 attempts at my dealer to admit they did something to my neighbor's Prius to reduce the rattle. They apparently bend the pad retainer springs to reduce the clatter that occurs when driving over rough pavement, or Botts dots.
I can reproduce this in EVERY 2010 Prius I have driven, Every one! Yet the dealer "can't reproduce it." It's a simple test: drive over Botts dots (lane divider dots) with your window down and then apply the brakes. Guaranteed the "clatter" will go away upon brake application. Simple.
Toyota's position is that "..it isn't a safety issue." It might not be, but having a sound like that come from your suspension is ridiculous.

this is a known issue. (at least for many on this board) so far, i have yet to come across an official fix from toyota. It took 3 attempts at my dealer to admit they did something to my neighbor's prius to reduce the rattle. They apparently bend the pad retainer springs to reduce the clatter that occurs when driving over rough pavement, or botts dots.
I can reproduce this in every 2010 prius i have driven, every one! Yet the dealer "can't reproduce it." it's a simple test: Drive over botts dots (lane divider dots) with your window down and then apply the brakes. Guaranteed the "clatter" will go away upon brake application. Simple.
Toyota's position is that "..it isn't a safety issue." it might not be, but having a sound like that come from your suspension is ridiculous.

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***thanks pixel! Your information was helpful. My wife was convinced that the noise was a result of my smelly running shoes in the back compartment. Seriously though, ...toyota says "it is not a safety issue". But is it "a wear issue"?

This is a known issue. (at least for many on this board) So far, I have yet to come across an official fix from Toyota. It took 3 attempts at my dealer to admit they did something to my neighbor's Prius to reduce the rattle. They apparently bend the pad retainer springs to reduce the clatter that occurs when driving over rough pavement, or Botts dots.
I can reproduce this in EVERY 2010 Prius I have driven, Every one! Yet the dealer "can't reproduce it." It's a simple test: drive over Botts dots (lane divider dots) with your window down and then apply the brakes. Guaranteed the "clatter" will go away upon brake application. Simple.
Toyota's position is that "..it isn't a safety issue." It might not be, but having a sound like that come from your suspension is ridiculous.

Click to expand...

Interesting info. Shortly after 5k oil change I noticed this, so at 10k service I brought it to their attention. Found missing fasteners and sent me on my way. Sound remained and I came back 150 miles later, and this time had mechanic in car to duplicate. Front struts were ordered and installed next day. They took all of 3 hours then told me no help. Front caliper bolt were next targeted and ordered. They used remote mics to isolate. Going to allow them to put them in, but might let them know what you said. Mechanic did verify that even the new car on the lot made the same noise as you described. As the roads around my dealership are very good, we also used the botts and verified on both sides. It also sounded in the front and rear to me. Will see what happens. Thanks.

Me 2. My 2011 is driving me crazy with chattering/rattleling in the front over bumpy surfaces. Only noticeable when windows are open. Will have dealer look at when I take it in for the 5k checkup (currently have 4k)

I had this same problem a couple years ago on a used 91 Cadillac Allante. My regular mechanic couldn't diagnose the problem. My then-new son-in-law, a mechanic, and I diagnosed the problem by me repeatedly driving across a bump in our street while he stood at the curb and listened. He used some type of brake adhesive to solve the problem. I've since sold the car and the son-in-law turned out to be a better mechanic than husband and ended up in jail. But that's another story...

Good news everyone!!! Or at least those who are having the rattling problems with their brakes. Like others have posted on here Toyota issued a TSB (Toyota Service Bulletin) for this problem. When I took my Gen III Prius to Phil Bachman Toyota yesterday for my 5000 mile service, I informed them again that my brakes were still making the rattling noise and I also told them that Toyota had issued a TSB and they need to fix the problem with my car.

The service manage found the TSB and had the technician check my brakes out and she agreed that all 4 wheels needed the fix. I am assuming it is shims or something. They did however have to order the parts and I my beloved black beauty will be fixed and rattle free. :cheer2:

Well I had my brakes fixed yesterday. With the exception of some really rough bumps because of road construction, my driving experience was as it should be. Quiet. I am so glad that Toyota finally ordered the TSB and recognised that there was a problem and fixed it before they were made to issue a recall. :cheer2:

I believe that I have this same issue. I'm going to get it taken care of ASAP.
Funny thing is that I may have had the same issue on my previous car as well (VW Passat). Now I can pass along this info to the guy who bought it as another area to explore to chase down that noise.
Thanks PriusChat people!

@El Dobro: Locate the highest sticker inside the driver’s door frame – it is black with white lettering. In the upper right corner of the sticker, you will find the manufacture date of your car in the format of MM/YY.

Also, just above the bar code in that sticker is the VIN #. Look at digit # 11 and it should have one of three possible values:

0 = made in Tsutsumi plant line # 1 1 = made in Tsutsumi plant line # 25 = made in Fugimatsu plant.

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